Combustion & Burnershttps://www.industrialheating.com/rss/2655-combustion-burners
en-usMeeting Increasingly Strict NOx Emissions Standards
The global industrial sector has never placed greater demands on manufacturers. Companies in a range of industries must optimize performance and minimize waste while holding the line on emissions, regardless of the regulatory requirements in their state, region or country. ]]>
http://www.industrialheating.com/articles/94919Mon, 29 Apr 2019 11:00:00 -0400https://www.industrialheating.com/articles/94919-meeting-increasingly-strict-nox-emissions-standards
1-PH0217-Maxon-Figure-1-Close-up-view-of-a-burner-flame-FIGURE 1. This closeup view shows a burner flame using a swirl design to mix the air and fuel and lower NOx. The good mixing it provides will improve combustion uniformity to reduce peak flame temperature and lower NOx.
2-PH0217-Maxon-Figure-2-Low-NOx-line-style-burnerFIGURE 2. In a low NOx line-style burner, the cut-outs and holes in the mixing plates cause the air and fuel to mix thoroughly, ensuring as uniform combustion as possible.
3-PH0217-Maxon-Figure-3-Cutaway-of-self-recuperative-burner-FIGURE 3. For applications requiring higher temperatures, one common method to reduce NOx is through the use of flue-gas recirculation (FGR), as shown with the red arrows in this cutaway of a self-recuperative burner in a radiant tube.
4-PH0217-Maxon-Figure-4-Air-Staging-HolesFIGURE 4. The telltale sign of a burner designed for staged combustion is an extra set of holes or slots for the secondary stream to travel through and into the combustion chamber. Here, two types of air staging are shown: holes on the left, slots on the right.
IHEA Announces Fall Seminars, Business Conference
The Industrial Heating Equipment Association (IHEA) announced that the 2019 Fall Seminars and Fall Business Conference will be held in Cleveland, Ohio, Sept. 24-26. The technical seminar series will be held on Tuesday and Wednesday, followed by the Fall Business Conference on Thursday at the Intercontinental Cleveland. The Combustion Seminar and the Safety Standards and Codes Seminar will take place concurrently over both days. There will also be two separate one-day seminars on infrared heating and induction technology. Attendees of all four seminars will enjoy access to IHEA’s tabletop exhibition and reception on the afternoon of Tuesday, Sept. 24.
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http://www.industrialheating.com/articles/94864Wed, 03 Apr 2019 09:00:00 -0400https://www.industrialheating.com/articles/94864-ihea-announces-fall-seminars-business-conference
Registration Open for IHEA Online Learning Course
Registration is open for IHEA’s Fundamentals of Industrial Process Heating online learning course, which begins on April 15. The course is ideal for students who wish to further their studies at home or work in a flexible web-based, distance-learning format. It’s an affordable alternative to campus-based classes and allows students to go at their own pace.
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http://www.industrialheating.com/articles/94762Fri, 08 Feb 2019 15:00:00 -0500https://www.industrialheating.com/articles/94762-registration-open-for-ihea-online-learning-course
12 Helpful Tips for Thermprocess 2019
Here are 12 tips that you will find extremely helpful when attending Thermprocess, GIFA, METEC and NEWCAST 2019 June 25-29 at the fairgrounds in Düsseldorf, Germany.
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http://www.industrialheating.com/articles/94761Fri, 08 Feb 2019 13:00:00 -0500https://www.industrialheating.com/articles/94761-helpful-tips-for-thermprocess-2019
State of the Industry 2018: Job Satisfaction, Skill Development and Company Challengesbill@industrialheating.com (Bill Mayer)
How many hours per week do you work on average? How satisfied are you with certain elements of your job? What will be the biggest challenge for your company in the next 12 months?]]>
http://www.industrialheating.com/articles/94701Wed, 16 Jan 2019 00:00:00 -0500https://www.industrialheating.com/articles/94701-state-of-the-heating-industry-2018---job-satisfaction-skill-development-and-company-challenges
ih0119-state-lead-900ih0119-state-photo2-900ih0119-state-hours-900Fig. 1.&nbsp;Hours worked per week
ih0119-state-by-the-numbers-900Fig. 2.&nbsp;Satisfaction with job-specific aspects
ih0119-state-culture-900Fig. 3.&nbsp;Company culture on embracing technology
ih0119-state-biggest-900Fig. 4.&nbsp;Biggest future challenges
Reader-Rated Melting/Forming/Joining Articlesreed@industrialheating.com (Reed Miller)
Once again, our readers weigh in on the best articles in 2018. This time it is in the melting/forming/joining category. Interested in what they have to say? Check out the list that follows.]]>
http://www.industrialheating.com/articles/94558Tue, 06 Nov 2018 00:00:00 -0500https://www.industrialheating.com/articles/94558-reader-rated-meltingformingjoining-articles
ih1118-mfj-lead-900ih1118-mfj-aluminum-Scrap-900ih1118-mfj-combustion-technologies-900ih1118-mfj-playing-with-Fire-900ih1118-mfj-process-Thermal-900ih1118-mfj-torch-brazing-900ih1118-mfj-using-induction-900ih1118-mfj-vacuum-diffusion-900ih1118-mfj-end-image-900The Value of Scheduled Combustion-System Maintenance
My colleagues and I have been in the combustion business for many years and have a wide range of experience with single-burner and multi-burner applications. What follows is some basic information concerning the maintenance and adjustment of combustion systems.]]>
http://www.industrialheating.com/articles/94500Mon, 08 Oct 2018 00:00:00 -0400https://www.industrialheating.com/articles/94500-the-value-of-scheduled-combustion-system-maintenance
ih1018_igc-value_lead-900ih1018_igc-value_fig1-900Typical natural gas fuel train.
Pulse Firing Doubles Capacity and Cuts Fuel Costsinfo@combustionsafety.com (Katie Huller)
In multiple-burner installations on industrial ovens and furnaces, pulse-firing techniques can improve temperature uniformity, reduce emissions and cut overall fuel costs. Is it right for your process?]]>
http://www.industrialheating.com/articles/94493Thu, 04 Oct 2018 00:00:00 -0400https://www.industrialheating.com/articles/94493-pulse-firing-doubles-capacity-and-cuts-fuel-costs
ih1018_igc_lead-900ih1018_igc_fig1-900Fig. 1. In pulse firing, the heat input is controlled on each individual burner by modulating the frequency of high and low firing ranges. This results in good process control, flexibility and precision.
ih1018_igc_fig2-900Fig. 2. The control-loop setup screen allows the operator to modify PID settings and provides a pictorial view of the current switch points.
ih1018_igc_fig3-900Fig. 3. The control-loop setup screen identifies which set of PID parameters is in use. The control-loop setup HMI screen and actual temperature trend are pictured.
ih1018_igc_fig4-top-900Fig. 4. (Top) The system control screen displays the control and status information required by the operator during normal operation. For example, the HMI screens show which burners are at high fire, low fire or off. If an equipment or control problem arises, permissive screens are available that will inform the operator of all inputs that the PLC code is expecting for a certain function. These tools point maintenance personnel to the exact location of a given problem and reduce the time it takes for troubleshooting.
ih1018_igc_fig4-bottom-900Fig. 4.(Bottom) The system control screen displays the control and status information required by the operator during normal operation. For example, the HMI screens show which burners are at high fire, low fire or off. If an equipment or control problem arises, permissive screens are available that will inform the operator of all inputs that the PLC code is expecting for a certain function. These tools point maintenance personnel to the exact location of a given problem and reduce the time it takes for troubleshooting.
Combustion Technologies Improve Melting-Furnace Productivityhttp://www.industrialheating.com/articles/94274Wed, 13 Jun 2018 00:00:00 -0400https://www.industrialheating.com/articles/94274-combustion-technologies-improve-melting-furnace-productivity
Working Toward the Ideal Radiant-Tube Performancehttp://www.industrialheating.com/articles/94267Mon, 11 Jun 2018 00:00:00 -0400https://www.industrialheating.com/articles/94267-working-toward-the-ideal-radiant-tube-performance
Radiant-tubeIllustration of a common “W”-shaped radiant tubeFig. 1. Illustration of a common “W”-shaped radiant tube demonstrates the issue of temperature non-uniformity in a typical application; heat increases near the burner tip but dissipates further along the tube.Energy flows in a typical recuperative radiant tubeFig. 2. Energy flows in a typical recuperative radiant tube are shown, indicating the energy input, energy transfer to the load, energy recovered by the recuperator and energy lost from the exhaust.Changes in available heat dependent upon variablesFig. 3. Changes in available heat dependent upon varying levels of oxygen and excess air, highlighting the importance of proper tuning.Tube temperature vs. receiver temperatureFig. 4. Operating radiant tubes at 100% input can lead to portions of the tube operating beyond the material temperature limit as the heated product gets hotter.A real-world radiant-tube applicationFig. 5. A real-world radiant-tube application. One can visually notice areas in the tube glowing brighter than others, indicating temperature non-uniformity.Fives North American 4723LNx Radiant-tube BurnerFig. 6. Fives North American 4723LNx low-emissions radiant-tube burnerFives North American 8480-series Radiant-tube RecuperatorFig. 7. Fives North American 8480-series high-efficiency radiant-tube recuperatorFives North American TBRT III regenerative radiant-tube burnerFig. 8. Fives North American TBRT III regenerative radiant-tube burnerTop 5 Most Popular Articles of 2017
Here’s a look at the five most viewed articles on Industrial Heating’s website in 2017 (based on page views from Jan. 1 to Dec. 31). Enjoy!
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http://www.industrialheating.com/articles/94008Tue, 23 Jan 2018 11:00:00 -0500https://www.industrialheating.com/articles/94008-top-5-most-popular-articles-of-2017
Fives' High-Velocity Burnerhttp://www.industrialheating.com/articles/93875Fri, 10 Nov 2017 06:00:00 -0500https://www.industrialheating.com/articles/93875-fives-high-velocity-burner
State of the Thermal-Processing Industry 2017bill@industrialheating.com (Bill Mayer)
In what is becoming an annual tradition, Industrial Heating, with assistance from BNP Media Market Research, polled qualified subscribers on a variety of industry- and job-related issues. Our goal is simple. We want to find out more about the current state of employment in the thermal-processing industry.
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http://www.industrialheating.com/articles/93783Wed, 04 Oct 2017 00:00:00 -0400https://www.industrialheating.com/articles/93783-state-of-the-thermal-processing-industry-2017
EmployeesIndustrial Heating, with assistance from BNP Media Market Research, polled qualified subscribers on a variety of industry- and job-related issues. E Instruments International's Portable Emissions Analyzer
The E8500 PLUS emissions analyzer is a complete portable tool for EPA compliance-level emissions monitoring and testing.
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http://www.industrialheating.com/articles/93749Wed, 13 Sep 2017 00:00:00 -0400https://www.industrialheating.com/articles/93749-e-instruments-internationals-portable-emissions-analyzer
Improved NOx Limitation Standard to Reflect Combustion Efficiency
In many locations throughout North America, nitrogen oxide (NOx) emissions of gas-heated furnaces are limited by law or code. This is typically the case in urban areas or in places where special topographical characteristics intensify the negative local and regional effects of NOx emissions.]]>
http://www.industrialheating.com/articles/93581Mon, 12 Jun 2017 00:00:00 -0400https://www.industrialheating.com/articles/93581-improved-nox-limitation-standard-to-reflect-combustion-efficiency
NOx EmissionsIllustration of FLOXFig. 1.&nbsp; Illustration of FLOX&reg; combustion technology and effect on temperature profile (courtesy of WS)
Efficiencies of different types of gas-burner technologyFig. 2. Efficiencies of different types of gas-burner technology (courtesy of WS)
Efficiency Ratio/Correction FactorFig. 3. Cold-air burner vs. regenerative burner &ndash; illustration of efficiency ratio, correction factor, traditional one-dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for exemplary furnace application as defined in the article is highlighted in green.
NOx Emissions/LimitsFig. 3. Cold-air burner vs. regenerative burner &ndash; illustration of efficiency ratio, correction factor, traditional one-dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for exemplary furnace application as defined in the article is highlighted in green.
Annual Natural Gas ConsumptionFig. 3. Cold-air burner vs. regenerative burner &ndash; illustration of efficiency ratio, correction factor, traditional one-dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for exemplary furnace application as defined in the article is highlighted in green.
Annual NOx emissionsFig. 3. Cold-air burner vs. regenerative burner &ndash; illustration of efficiency ratio, correction factor, traditional one-dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for exemplary furnace application as defined in the article is highlighted in green.
Bloom Engineering Commissions Lab Furnace
Bloom Engineering Co. of Pittsburgh, Pa., rebuilt, upgraded and commissioned a laboratory furnace to refine its latest generation of ultra-low-NOx regenerative burners.
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http://www.industrialheating.com/articles/93546Tue, 23 May 2017 09:15:00 -0400https://www.industrialheating.com/articles/93546-bloom-engineering-commissions-lab-furnace
Combustion Resources 2017reed@industrialheating.com (Reed Miller)
The goal of this article is to improve your awareness of resources that exist to help you make better sense of combustion-related issues and answer your combustion-related questions.]]>
http://www.industrialheating.com/articles/93446Tue, 11 Apr 2017 00:00:00 -0400https://www.industrialheating.com/articles/93446-combustion-resources-2017
ih0417-igc-lead-900ih0417-igc-heat_supply-900.jpgih0417-igc-hot-parts-900.jpgih0417-igc-photo-900.jpgIHEA Fall Seminars Coming to South Carolina
The Industrial Heating Equipment Association (IHEA) will hold its 2017 Fall Seminars at the Westin Poinsett in Greenville, S.C., Sept. 19-20.
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http://www.industrialheating.com/articles/93432Wed, 29 Mar 2017 15:00:00 -0400https://www.industrialheating.com/articles/93432-ihea-fall-seminars-coming-to-south-carolina
Aluminum Scrap Recycling with Twin-Chamber Melting Furnace
Scrap recycling with the twin-chamber melting furnace (TCF®) has become state-of-the-art worldwide. The latest installations show that the TCF fulfills the complex requirements of scrap processing regarding environment, safety and metal yield.]]>
http://www.industrialheating.com/articles/93327Thu, 09 Feb 2017 00:00:00 -0500https://www.industrialheating.com/articles/93327-aluminum-scrap-recycling-with-twin-chamber-melting-furnace
TCFFig. 1. Twin-chamber melting furnace (TCF&reg;)
Process FlowFig. 2. Process flow diagram of TCF&reg;
System SchematicFig. 3. Central regenerator system schematic
Bloom Engineering Expands Project Management Department
In order to handle a bigger project load, Bloom Engineering expanded its Project Management Department.
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http://www.industrialheating.com/articles/93313Wed, 01 Feb 2017 12:00:00 -0500https://www.industrialheating.com/articles/93313-bloom-engineering-expands-project-management-department
2016 Feature Article Bibliography

This is a complete list of all the feature articles – by topic – that appeared in Industrial Heating in 2016. The month each article appeared in is included with page number. All articles are hyperlinked for your convenience.

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http://www.industrialheating.com/articles/93282Thu, 19 Jan 2017 11:30:00 -0500https://www.industrialheating.com/articles/93282-feature-article-bibliography
State of the Thermal-Processing Industry 2016
For the second year in a row, we asked readers about the state of the thermal-processing industry.]]>
http://www.industrialheating.com/articles/93248Thu, 05 Jan 2017 08:00:00 -0500https://www.industrialheating.com/articles/93248-state-of-the-thermal-processing-industry-2016
Employee and Mentorih0117-state-embraceih0117-state-hoursih0117-state-salaryih0117-state-satisfactionih0117-state-numbersHigh-Velocity Burner Designed for High Temperatures
The SuperFlame high-velocity burner – with nine available models in capacities ranging from 150,000 BTU/hour to 5 MM BTU/hour – is designed for process temperatures up to 2500°F (1371°C).
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http://www.industrialheating.com/articles/93158Tue, 08 Nov 2016 00:00:00 -0500https://www.industrialheating.com/articles/93158-high-velocity-burner-designed-for-high-temperatures
How to Maximize Burner Efficiency
Because energy costs are a major factor for many industrial processes, it makes sense to carefully analyze how the natural gas is being used and whether the system is running at peak efficiency.]]>
http://www.industrialheating.com/articles/92914Thu, 09 Jun 2016 00:00:00 -0400https://www.industrialheating.com/articles/92914-how-to-maximize-burner-efficiency
Natural Gas
The challenges of effectively burning natural gas date back much further than one might think.
Air/Fuel Ratio Control
A mass flow air/fuel ratio control system controls burner performance by metering the incoming air/gas flows and modulating the flows via precision actuators.
Natural Gas Usage
The industrial sector currently consumes 27 percent of the natural gas in the United States with projected increases of 6.25 percent between 2014 and 2021.
Source: EIA Manufacturing Energy Consumption Survey (MECS), 2010
Burners
AdvanTek WRT burners are designed for annealing and galvanizing lines to reduce pollutant emissions and improve energy efficiency.
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http://www.industrialheating.com/articles/92873Tue, 10 May 2016 00:00:00 -0400https://www.industrialheating.com/articles/92873-burners
Portable Emissions Analyzer
E8500 PLUS is a complete portable tool for EPA compliance-level emissions monitoring and testing.
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http://www.industrialheating.com/articles/92827Fri, 08 Apr 2016 00:00:00 -0400https://www.industrialheating.com/articles/92827-portable-emissions-analyzer
Radiant Tube Combustion System Upgrade at Akron Steel Treatingmcornelius@selas.com (Mitch Cornelius)
Indirect-fired heat-processing equipment is crucial for many heat-treatment processes in which the product or load must not come into direct contact with the flame or products of combustion.]]>
http://www.industrialheating.com/articles/92814Tue, 05 Apr 2016 00:00:00 -0400https://www.industrialheating.com/articles/92814-radiant-tube-combustion-system-upgrade-at-akron-steel-treating
Indirect-fired heat-processing equipmentEnergy Sabre 600 Cutaway
Fig. 1. Energy Sabre 600 cutaway with Si-SiC tube set. Inner tube is segmented to allow for distortion of the tube over time.
Tube Temperature and Distance From Burner
Fig. 2. Hot spot above average (HSOA) of 42.5&deg;F was found at a furnace temperature of 1725&deg;F, with the burner firing at a rate of 125,000 Btu/hour and 15% excess air.
Real-time Production Load Chart
Fig. 3. Real-time production load before vs. after installation
Fuel Consumption Chart
Fig. 4. Fuel consumption before vs. after installation
Thermal Processing History From the 1900s to Present Day
In the early 20th century, Industrial Heating came on the scene. In this historical overview (decade by decade), we take a look at metallurgy and how the steel industry was becoming big business. ]]>
http://www.industrialheating.com/articles/92789Wed, 16 Mar 2016 00:00:00 -0400https://www.industrialheating.com/articles/92789-thermal-processing-history-from-the-1900s-to-present-day
Ultra-Low-NOx Burner Retrofits for Aluminum Furnaces
Upgrading burners is often an effective way to achieve process improvements such as increasing productivity, decreasing fuel use and/or minimizing NOx and CO2 formation.]]>
http://www.industrialheating.com/articles/92703Fri, 05 Feb 2016 00:00:00 -0500https://www.industrialheating.com/articles/92703-ultra-low-nox-burner-retrofits-for-aluminum-furnaces
Sample cold-air to hot-air ultra-low-NOx conversion
Fig. 1. Sample cold-air to hot-air ultra-low-NOx conversionDual-head regenerative burner system
Fig. 2. Dual-head regenerative burner system
Dual-head regenerative system
Fig. 3. Dual-head regenerative system &ndash; burner &ldquo;A&rdquo; firing (left), burner &ldquo;B&rdquo; firing (right)
Expected NOx and CO2 of cold-air and hot-air ultra-low NOx burners
Table 1. Expected NOx and CO2 of cold-air and hot-air ultra-low NOx burners
Expected NOx and CO2 of cold-air, hot-air and regenerative ultra-low-NOx burners
Table 2. Expected NOx and CO2 of cold-air, hot-air and regenerative ultra-low-NOx burners
Combustion Videos Offer On-Demand Training to IHEA Members
Videos based on the combustion seminar the Industrial Heating Equipment Association (IHEA) has conducted annually for 46 years allow members of the organization to provide employee training at no cost.
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http://www.industrialheating.com/articles/92695Wed, 27 Jan 2016 16:45:00 -0500https://www.industrialheating.com/articles/92695-combustion-videos-offer-on-demand-training-to-ihea-members